ABB MV Drives in Power

ABB drives in power generationMedium voltage drives for more efficient and reliable plant operation

ABB � - ABB drives in power generation

ABB ABB drives in power generation - �

Variable speed drives improve the heat rate and net power output and reduce operating costs.

ABB – the world’s leading supplier of variable speed drives for the power generation industry

Efficient plant operationToday, power producers operate in a highly competitive marketplace. Business pressure from market liberalization and rising fuel costs require every producer to look for the most effective ways to convert a bigger share of fuel’s energy into salable kWh. Improving the heat rate of power plants is becoming increasingly important.

A thermal power plant usually consumes 5 – 8% of the electricity it produces. Pro-cesses driven by electric motors typically consume 80% of this electricity. Imple-menting electric Variable Speed Drives (VSD) improves the heat rate by increasing the efficiency of these processes.

GT starters, drives for fuel gas booster compressors, boiler (HRSG) feed-water pumps and cooling water pumps

Drives for boiler feed-water-, cooling water-, circulation water pumps, FD and ID fans

Drives for water circulation pumps in industrial and municipal combined heat and power (CHP) plants

Drives for conveyors and coal mills

Drives for ID booster fans, limestone slurry feed- and absorbent circulation pumps and oxidation air compressors

Soft starters for hydro turbines

Drives for geothermal power plants and soft starters for synchronous condensers

Drives for feed-water, condensate recirculation and cooling-water pumps

Gas turbine power plants

Pumped storage hydro power plants

Selective Catalytic Reduction, Flue Gas Desulphurization

Fuel handling

District heating, Combined Heat and Power

Steam generating boilers, waste incinerators

Renewable energy

Nuclear power plants

Cost-efficient operational flexibility is the key to increased production during low and peak demand. An improved heat rate and power output result in higher profitability and faster return on investment. Several small capacity improvements can be an alternative to an investment in a completely new power plant.

The investment in variable speed drives increases plant availability and flexibility through improved process control and reduces emissions and maintenance costs.

ABB supplies drives products and systems for various kinds of processes and applications in the power generation industry:


Flow and pressure controlDemand for electrical energy varies over the year, during the day and on an hourly basis. Even at the constant base-load station, the required flow of a fan or a pump varies due to changes in ambient conditions or fuel properties. Due to these varying conditions a continuous control of the processes and equipment, such as centrifugal fans and pumps, is required.

Benefits of variable speed drives

• High availability

• Fast and precise process control under

all conditions

• Minimized energy consumption

• Reduced emissions

• Minimized actuator equipment

• Soft starting features for a longer lifetime

of electrical and mechanical equipment

Benefits

Variable speed drives for more efficient and reliable plant operation.

Saving potential

Mechanical vs. electrical controlProcesses driven by pumps or fans are usually controlled either electrically with variable speed drives, or mechanically with inlet guide vanes, throttling valves or hydraulic couplings.

With the mechanical fixed-speed solution, it is practically impossible to achieve the optimal process efficiency over the whole control range.With the mechanical variable-speed solution the losses in the hydraulic coupling itself reduce the overall system efficiency.An increase in production capacity usually requires a costly reconstruction of the whole process.

With electric variable speed drives, changing the production volume is simply achieved by changing the motor speed. This saves energy, decreases CO2 emissions and minimizes the total operating costs.

Power consumption for various pump control methodsElectric variable speed drives allow fans and pumps to be operated at the BEP (Best Efficiency Point) under all operating conditions, thereby achieving maximum process efficiency. Electric variable speed drives are the most efficient control method. Electrical Mechanical

Variable speed

Fixed speed

variable speed hydraulic coupling drive

on-off throttling valve or inlet guide vane


Soft startingAccelerating rotating machinery with heavy load torque and/or high mass moment of inertia, such as ID fans and synchronous condensers, imposes large stresses on the electrical supply network and on the mechanical parts of the shaft string. A direct-on-line started electric motor can cause starting currents of up to six times the nominal current, or more. This will cause voltage drops that are likely to disturb the process, especially if the supply network is weak.

Energy savings and reduced emissionsEnergy saving has never been higher on the agenda than today. People have become increasingly aware of the correlation between wasting energy and environmental damage and acknowledge the benefits of conserving energy by technical means.

Since pumps and fans typically run at partial load, huge energy savings can be achieved by controlling their speed with variable speed drives. A small reduction in speed can make a big reduction in the energy consumption. A pump or a fan running at half speed consumes as little as one eighth of the energy compared to one running at full speed.

By employing variable speed drives on centrifugal pumps and fans instead of throttling or using inlet guide vanes, the energy bill can be reduced by as much as 60%. Consequently, electric variable speed drives help to reduce NOx and CO2 emissions.

Soft starting with variable speed drives results in the following benefits:• No process disturbance due to voltage drops;

no trips of other electrical devices connected to the same bus

• No excessive thermal or mechanical stress on the motor, resulting in a longer lifetime

• Immediate start-up without warming-up delay (e.g. steam turbines)

• Controlled and smooth start-up

ABB has more than 30 years experience in the design and manufacturing of static starting devices, which became the standard starting technology for heavy-duty gas turbines and pumped storage hydro turbines.

Comparison of investment costs and energy losses of different control methods.*

*Calculated for a 1300 kW (1740 hp) pump application, for three years operation


Variable speed drives for power generation applications

Various processes and applications in the power industry benefit from the implementation of variable speed drives.

Pumps

• Boiler feed-water pump

• Condensate extraction pump

• Cooling water pump

• District heating circulation pump

• Limestone slurry feed- and absorbent circulation pump

Fans

• Primary air fan

• Secondary air fan

• ID fan

• ID booster fan

Other

• Conveyor

• Coal mill

• Oxidation air compressor

• Gas turbine starter

• Fuel gas booster compressor

Flue gas fans High control accuracy, excellent energy economy and reduced maintenance costs are achieved with variable speed drives for all fans in the power generation process, including Forced Draft (FD), Induced Draft (ID) and cooling tower fans.

Feed-water pumpsFeed-water pumps are characterized by high reliability requirements and fairly high dynamics during plant load changes. They normally make the biggest contribution to the plant's own energy consumption. Traditionally, pump drivers have been selected focusing on reliability at the expense of efficiency. With today’s variable speed drive technology both targets can be met without compromise. Furthermore, mechanical mainte-nance costs can be reduced by controlling the feed-water flow with variable speed drives instead of throttling control valves.


Soft starting During the starting process, variable speed drives act as soft starters. They progressively increase the motor voltage and frequency and smoothly accelerate the load to its rated speed, eliminating the stress on electrical and mechanical equipment. Maintenance costs will be reduced and the lifetime of the equipment extended. High starting currents and voltage dips in the supply network, which might cause process disturbances, are eliminated.


ABB offers the entire range of medium voltage drives and soft starters for applications in the power range from 315 kW to more than 100 MW.

ACS 5000The ACS 5000 can be applied to standard industrial motors (induction and synchronous) up to 6.9 kV.

The ACS 5000 is ideal for power plants where applications such as Induced and Forced Draft fans, feed-water and cooling- water pumps are usually mechanically controlled. Retrofitting these high-powered applications with the ACS 5000 will result in significant improvements in efficiency and reliability.

Medium voltage drives

ACS 1000 ACS 5000 ACS 6000 MEGADRIVE-LCI

ACS 1000The ACS 1000 medium voltage drive is an unbeatable solution for auxiliary processes in the power industry. Due to its unique output sine filter, that eliminates common mode voltages and voltage reflections, the ACS 1000 is suitable for both retrofit applications and new standard motors.

The ACS 1000i, a medium voltage drive with integrated isolation transformer and input contactor, is the latest member of the ACS 1000 product family.

ACS 6000 ABB’s ACS 6000 is a modular drive designed for the most dynamic and powerful single or multi-motor applications for both synchronous and induction motors.

Inter-related motors can be connected to the same ACS 6000 via a common DC bus, enabling multi-machine operation with only one supply unit. For applications such as conveyor belts with up- and downhill conveying, the common DC-bus principle offers a solution with optimum efficiency and energy flow between motors of motoring and generating mode.

For more than 100 years ABB has provided drive products and systems to customers in different industries. ABB’s unrivalled experience in AC drives technology, combined with its long experience in the field of power generation, results in innovative drive solutions with unsurpassed performance and reliability.

MEGADRIVE-LCIABB’s MEGADRIVE-LCI is an optimal solution for high voltage and high power converter applications. They are also available as soft starters for applications with synchronous machines.

Standard designs are available for ratings up to 72 MW, engineered designs for more than 100 MW.


Low parts countThe fewer the parts the higher the reliability. ABB uses high power semiconductor switching devices and a topology that brings down the parts count to a minimum.

Fuseless designAll ABB medium voltage drives are designed to operate safely without fuses. This results in less spare parts and fast re-starting should an overcurrent trip occur.

EncoderlessEncoders have an exposed position on the motor and are known to cause failures. ABB's medium voltage drives can operate without encoder.

Technology highlights

Reliability is the main guiding principle of ABB's research and development activities for medium voltage drives.

Direct Torque Control (DTC)ABB’s award-winning control platform,

Direct Torque Control (DTC), results in the highest torque and speed performance ever achieved in medium voltage drives. Control of the drive is immediate and smooth under all conditions.

Power Loss RideThroughDue to its RideThrough function, the drive system is able to withstand disturbances of the power supply. The drive will continue to operate in an active but non-torque producing mode if the incoming supply voltage is cut off. The drive will be active as long as the motor rotates and generates energy to the drive. It will resume normal operation immediately upon return of power supply.

Superior semiconductor switching devicesABB has developed a high power switch called IGCT (Integrated Gate Commutated Thyristor) to allow the use of modern control algorithms, which can eliminate harmonics, improve dynamic response time, and maintain or even control the power factor. This results in a reliable, compact and service-friendly drive.

The diode and the line commutated thyristor still hold the top position for very high power, lowest losses and highest reliability, but they do not allow the use of modern control algorithms.

Low lossesThe inherently low total losses of the IGCT require low cooling capacity and small cooling equipment.

DriveWare, the tools to increase availability The ACS platform incorporates a set of user-friendly tools.

DriveWindow is an advanced, easy-to-use tool for commissioning, maintenance and remote diagnostics and monitoring of ABB drive systems.

DriveOPC is a software package which allows communication between Windows applications and ABB drives.

DriveSupport is a simple, clear and concise multimedia-based service tool, which provides clear instructions for troubleshooting and servicing drives.

ABB 10 - ABB drives in power generation

ABB can offer the complete variable speed drive system or assist in selecting components that match the process requirements. ABB’s equipment is known for its state-of-the-art technology, high efficiency and reliability and worldwide support.

Components of variable speed drive systems

Input isolation transformersAn input isolation transformer has two functions: it adjusts the network supply voltage to match the selected converter and it protects the motor from common-mode voltages. ABB input isolation transformers are specifically designed for operation with variable speed drives.

ABB's input isolation transformers are available for all ratings and primary voltages. Oil or dry type transformers are available for indoor or outdoor mounting. The separate transformer allows flexible installation, which can be next to the drive or, when space is limited, in another location.

An electric variable speed drive system consists of input isolation transformer, frequency converter and electric motor.

High voltage motorsABB’s high voltage motors have earned an excellent reputation for performance and reliability. The product range consists of both induction and synchronous motors.

Induction motors are the workhorses of the industry due to their versatility, reliability and simplicity. In the power range up to 10 MW, a squirrel cage induction motor is usually the first choice. They are available up to 18 MW.

Synchronous motors are typically considered for higher power ratings (e.g. above 8 MW to more than 100 MW). In addition to their high power capabilities, synchronous motors offer the benefits of high efficiency and high performance through the utilization of different rotor designs.

Induction motor Input isolation transformer

ABB ABB drives in power generation - 11

• Supervision of installation and commissioning

• Training• Remote diagnostics• Customized maintenance contracts

• Local support• 24 x 365 support line• Spare parts and logistics network• Worldwide service network

Services for ABB’s medium voltage drives

Testing, service and support

ABB drives are backed by unrivalled service and support from the customer's initial inquiry throughout the entire life cycle of the drive system.

TestingABB is committed to ensuring the reliability of every drive it delivers. To verify that quality standards and customer requirements are fully met every component of a drive is subjected to thorough testing in ABB's modern test facilities.

Routine tests and functional tests form an integral part of the scope of supply of ABB's medium voltage drives. They are performed in accordance with international standards and ABB quality assurance procedures.

Additionally, ABB can perform a combined test with the complete drive system – including transformer, converter and motor – to verify the performance and to ensure a smooth integration into the customer’s facility.

Installation and commissioningSubstantial benefits can be gained from proper installation and commissioning of the equipment. Predictive testing and inspection, in addition to traditional operational parameter setting, done by ABB's qualified and certified commissioning engineers, will reduce start-up time, increase safety and reliability and decrease life-cycle costs. In addition, operators can be given practical training by experienced specialists on site.

Life-cycle managementABB‘s drive life-cycle management model provides customers with the maximum profit for their purchased assets by maintaining high availability, eliminating unplanned repair costs and extending the lifetime of the drive. Life-cycle management maximizes the value of the equipment and maintenance investment by:• providing spare parts and expertise through-

out the life cycle• providing efficient product support and

maintenance for improved reliability• adding functionality to the initial product

by following the upgrade path• providing a smooth transition to a new

technology at the end of the life cycle

TrainingExtensive training for ABB’s medium voltage drives can be provided at the ABB University. A range of training programs is offered from basic tutorials to programs tailored to the customer’s specific needs. -> www.abb.com/abbuniversity

Global network, local presence After sales service is an integral part of providing the customer with a reliable and efficient drive system. The ABB Group of companies operates in more than 100 countries and has a worldwide network of service operations. Wherever you are, ABB is there for you.

ABB 1� - ABB drives in power generation

ABB Switzerland LtdMedium Voltage DrivesCH-��00 Turgi / SwitzerlandTel +�1 �� Fax +�1 �� Email [email protected]

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ABB MV Drives in Power

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